DE10155140C1 - Production of a building plate used in industrial/domestic buildings comprises mixing a support layer with a solvent and/or retarder and water/feeding to a mold, applying heat insulating layer and solidifying, and applying a plaster layer - Google Patents

Abstract

Producing a building plate composed of a heat insulating layer and a plaster layer comprises mixing a support layer of 10-40 weight % brown coal filter ash and 60-90 weight % wet flue gas desulfurized gypsum with a solvent and/or retarder and water and feeding to a mold; applying a heat insulating layer likewise made from 10-40 weight % brown coal filter ash and 60-90 weight % wet flue gas desulfurized gypsum mixed with a solvent and/or retarder and water as a direct foam and solidifying for 10-60 minutes; and applying a plaster layer made from 10-40 weight % brown coal filter ash and 60-90 weight % wet flue gas desulfurized gypsum with additives and/or with addition of a waterproofing agent. Preferred Features: The waterproofing agent is produced by mixing a highly polymerized material produced from native oils and is mixed into the heat insulating layer and plaster layer. Mixing is carried out in a tubular mixer.

Description

The invention relates to a method for producing a from a base layer, a Thermal insulation layer and a plaster layer composite building board for the Use in residential and industrial construction.

Building boards for residential and industrial construction have been traditional for many years state of the art.

The proportionate use of power plant residues for the production of these Platten is considered to be known.

For example, DE-OS 31 21 256 A1 describes the production of a building board from plaster, Cement, fly ash, fillers and various fibers.

DE-OS 39 37 429 A1 describes the manufacture of a building reinforced with glass fibers plate explained, the mixture of 40-60 parts by weight of calcium sulfate hemihydrate, 40- 60 parts by weight of low-aluminate cement, 3-10 parts by weight of finely divided pebbles acid and up to 2 parts by weight of condenser, retarder and / or accelerator ger and possibly aggregates.

In addition, a method for the production of components, in particular Building boards and mixtures, known, with binders and foamed Gra nulates are mixed with water (DE-OS 198 36 227 A1). A is used as a binder thermally treated mixture of combustion residues, water-containing Substances and CaO used, this (as an additive) with from recycled Used glass foamed granules or similar porous materials and water ver mixes, if necessary then pressed into molds and hardened. As Combustion residues filter ash are used.

Furthermore, there is a method for producing components, in particular construction known plates in which a thermally treated mixture as a binder Combustion residues, water-containing substances and CaO are used, organic fibers being used as reinforcement (DE-OS 198 17 519 A1).  

A similar building board describes DE-OS 198 36 385, here a mixture of thermally treated combustion residues, water-containing substances and CaO is mixed with known foaming agents and water.

All of the solutions described are produced as single-layer building boards, so that either the heat-insulating or the strength-increasing features can be optionally improved. A prefabricated panel that can be used on all sides with The thermal insulation and strength properties are not described. In addition, it remains to be seen that these panels are only for interior construction are suitable because they have no moisture and frost resistant properties feature.

The invention has for its object to develop and use a building board places that overcomes the disadvantages of the prior art, in particular are extensive resistance to moisture and frost, increased thermal insulation and firmness demands for functionality with simple manufacturing technology and uncomplicated con structural structure required.

This is achieved according to the invention in that the entire plate in all layers is produced almost entirely from power plant residues in the form of a mixture of brown coal filter ash (BFA) and plaster of wet flue gas desulfurization (REA gypsum) treated in the temperature range from 100 to 600 ° C. , in which

• a) the base layer from the thermally treated mixture with a proportion of 10 to 40 M% BFA and 60 to 90 M% REA gypsum with the addition of an eluent and / or a retarder and water at a water / binder value of <0.5, preferably <0.4, and of aggregates in relation to the bandage mixed from 4: 1 to 1: 1 and put into a mold,
• b) then the thermal insulation layer from the thermally treated mixture a proportion of 10 to 40 M% BFA and 60 to 90 M% REA gypsum with addition a flow agent and / or a retarder and / or a synthetic Foaming agent and water with a water: binder value from 0.4 to 0.7, preferably 0.5 to 0.6, using a mixer as a direct foam  applied or by mixing the mixture described with a separately produced foam and also on the base layer applied according to a) and after a stiffening time of 10 to 60 min.
• c) then a plaster layer of the thermally treated mixture with a Proportion of 10 to 40 M% BFA and 60 to 90 M% REA gypsum with the addition of Aggregates in relation to the binder from 2: 1 to 4: 1 and / or below Mixing a hydrophobizing agent is brought.

The thermal pretreatment of almost the entire mixture of all three According to the invention, layers lead for the first time to the same and special materials All properties of the entire plate through calcination and new formation mental phases of the raw materials, which are predominantly power plant residues.

In addition to known construction chemicals, water repellents in particular are used re highly polymerized fabrics, made on the basis of native oils, are used. The thermal insulation layer is foamed using known synthetic materials Foaming agents, preferably in a so-called tube mixer, as a direct Ver foaming. The starting materials to be foamed must be highly dispersed Form without agglomerates. The water repellents are counter State of the art not applied to the plaster, but in the heat insulation and / or the plaster layer mixed. Hydrophobizing the plaster and The thermal insulation layer is of particular importance because it is only mals both outer layers of a plate with the same starting materials also the same have hydrophobic properties.

In particular, surprisingly occurs when the hydrophobicity is mixed agent with the special raw materials (thermally treated REA gypsum and BFA) a change in the crystal matrix so that a connection or attachment tion of water molecules is reduced or avoided.

This greatly reduces the absorbency of the capillary pores.

After stripping the building boards, they are subjected to a drying process. At this point, due to the peculiarity of the raw materials (high CaO _free content), a superimposed, novel process of opposing swelling (from the inside) and shrinking (from the outside) can be seen, so that no deformation occurs and the strength increases.

As part of a Decommissioning and reusability will become increasingly important in the future Building materials and elements in the recycling cycle are fully recyclable building board, which is essentially the same in all three layers Starting material has an increasing importance. First time with one Three-layer board no complex material separation into different components (Concrete, reinforcement and insulating materials) more. The plate is from this green de Completely recyclable without material separation.

Further advantages of the invention are:

manufacturing technology

The rapid hardening of the novel building material, which according to the invention in all three layers used equally leads to a faster er are sufficient for the minimum strength of all three layers required for demoulding For this reason, the effectiveness of the manufacturing process can be impact times of the molds are increased. Another advantage is the elimination of heat (steam) treatment required in the manufacture of concrete slabs, since the plates according to the invention their strength exclusively by air drying reasonable switching times from 7 to 12 hours, preferably 10 hours pass.

Construction and assembly

While with conventional concrete slabs, full heat protection is provided on the Insulation panels to be assembled (usually styrofoam) takes place at the to be provided with a spatula plaster, has the fiction board already without an additional insulation board over the required  Thermal protection and the desired surface design, which leads to an additional Chen reduction in construction costs and improved strength properties of the entire plate leads.

The invention will be explained in more detail below using an exemplary embodiment become.

The three-layer panels to be produced should have the following layer thicknesses:
Base layer: 100-180 mm
Thermal insulation layer: 100-150 mm
Plaster: 5-10 mm
so that ultimately a building board up to 340 mm thick is created.

A house building board for single-storey housing is to be manufactured. A concrete slab is produced as a base course, which is of concrete quality B 25 equivalent. Here, a thermally treated mixture of 30% BFA and 70% REA gypsum as a binder in proportion with 3.4 parts of aggregate (concrete gravel) Addition of 0.5% of a retarder, for example based on tartaric acid, and up to 2% of a flow agent, for example based on polycarboxylate ether (both based on the proportion of binder) and water in the ratio W / B = 0.4 mixed in a compulsory mixer and then applied in molds. To a stiffening time of approx. 45 min, a layer is applied to this base layer foamed thermal insulation plaster applied. This thermal plaster consists of egg nem thermally treated mixture of 30% BFA and 70% REA gypsum, which at a W / B value of 0.6 with the addition of 0.5% retarder, 2.0% superplasticizer as well compressed air is fed to the binder glue in a special device via fine nozzles becomes.  

After a further stiffening time of approx. 60 min, the surface of the ge foamed thermal plaster an approx. 5 mm thick layer of a hydrophobized Plaster applied. This in turn consists of the thermally treated Ge mix of 30% BFA and 70% REA gypsum, which in proportion with aggregates 3: 1 and mixed with water in a ratio of 0.8. This mixture a hydrophobizing agent, preferably a highly polymerized rubber, is added mixed. The multilayer plate can be removed from the mold after 10 h and dried further suitable storage.

Claims (3)

1. A process for producing a building board composed of a base layer, a thermal insulation layer and a plaster layer, characterized in that the entire board in almost all layers consists of power plant residue, in the form of a thermally treated mixture in the temperature range from 100 to 600 ° C Lignite filter ash (BFA) and gypsum of wet flue gas desulphurization (REA gypsum) is produced, whereby

• a) the base layer of the thermally treated mixture with a proportion of 10 to 40 M% BFA and 60 to 90 M% REA gypsum with the addition of a flow agent and / or a retarder and water at a water / binder value of <0, 5, preferably <0.4, and of additives in relation to the binding agent mixed from 4: 1 to 1: 1 and brought into a shape,
• b) thereupon the thermal insulation layer from the thermally treated mixture with a proportion of 10 to 40 M% BFA and 60 to 90 M% REA gypsum with the addition of a flow agent and / or a retarder and / or a synthetic foaming agent and water in a water / Binder value of 0.4 to 0.7, preferably 0.5 to 0.6, brought as a direct foaming by means of a mixer or produced by mixing the mixture described with a separately produced foam and likewise applied to the base layer according to a) and after a stiffening time of 10 to 60 min,
• c) then a plaster layer of the thermally treated mixture with a proportion of 10 to 40 M% BFA and 60 to 90 M% REA gypsum with the addition of additives in a ratio of 2: 1 to 4: 1 and / or with admixture to the binder a water repellent is brought.

2. The method according to claim 1, characterized in that as hydrophobicity In addition to the construction chemicals known per se, a high polymer Substance made on the basis of native oils and used in the warmth insulation layer and the plaster layer is mixed.   3. The method according to claim 1, characterized in that as a mixer Pipe mixer is used.